DEFON designs and manufactures custom 400Hz transformers for applications requiring high-frequency AC power conversion, compact magnetic designs, and reliable electrical performance.

Compared with standard 50/60Hz transformers, 400Hz transformers require different considerations in core material, flux density, winding design, insulation, thermal management, and power density.

We support custom transformer designs from engineering review and prototype development through production.

Custom 400Hz Transformer Engineering

A 400Hz transformer is not simply a standard 60Hz transformer operated at a higher frequency.

At 400Hz, the transformer can achieve a smaller and lighter magnetic structure, but core loss, winding loss, skin effect, proximity effect, temperature rise, and insulation requirements must be carefully evaluated.

DEFON can customize:

• Input / output voltage
• VA rating
• 400Hz operating frequency
• Single-phase or multi-phase configurations
• Core material and size
• Primary / secondary winding configuration
• Wire and insulation system
• Mounting dimensions
• Lead wires, terminals and connectors
• Shielding and electrostatic screen
• Temperature rise requirements
• Electrical and mechanical specifications

Typical Applications

400Hz transformers are commonly used in specialized power and electronic systems, including:

• Aerospace and avionics equipment
• Aircraft ground power systems
• Navigation and communication equipment
• Industrial electronic equipment
• Test and measurement equipment
• Power conversion systems
• Specialized AC power supplies
• Defense and other high-reliability electronic systems

For aerospace and other demanding applications, transformer design can be optimized for size, weight, efficiency, temperature rise, insulation and long-term reliability.

400Hz Transformer Design Considerations

Core Design

Core material and operating flux density directly affect core loss and temperature rise at 400Hz.

Winding Design

Higher operating frequency increases the importance of AC winding losses, including skin effect and proximity effect. Wire size, winding arrangement and layer construction must be properly selected.

Thermal Management

Compact 400Hz transformers can have relatively high power density. Thermal design is therefore an important part of the engineering process.

Insulation System

Primary-to-secondary insulation, layer insulation, creepage, clearance and dielectric strength are considered according to the application requirements.

Mechanical Design

For equipment with limited space, DEFON can optimize the transformer for specified dimensions, mounting method, terminals and lead configuration.

Custom 400Hz Transformer Manufacturer

DEFON provides custom transformer engineering based on your electrical and mechanical requirements.

You can provide us with a specification, drawing, existing transformer, sample, or application requirements. Our engineering team can review the design and recommend an appropriate magnetic structure, winding configuration and insulation system.

Typical project information:

Need a Custom 400Hz Transformer?

Send us your input voltage, output voltage, VA rating, frequency, dimensions and application.

DEFON Engineering will review your requirements and provide a custom solution.